Systems and methods for forming a composite structure

ABSTRACT

The present disclosure provides systems and methods for forming a composite structure comprising rotating a base layer of an apparatus for forming the composite structure about an axis of rotation, transferring carbon short fibers from a first vibratory feed ramp onto the base layer in order to form a plurality of fibrous layers in the composite structure, and vibrating the first vibratory feed ramp during the transferring the carbon short fibers. The base layer may comprise an annular shape.

FIELD

This disclosure generally relates to forming composite structures,specifically by distributing carbon short fibers on a loom or rotatingmold.

BACKGROUND

Composite structures are employed in various industries. Preparation ofcomposite structures should be economical. Additionally, each layer ofthe composite structure should be precisely made in terms of fibercontent and fiber distribution. An exemplary use for compositestructures includes using them as friction disks such as aircraft brakedisks, race car brake disks, clutch disks, and the like. Compositestructure disks are especially useful in such applications because ofthe superior high temperature characteristics of composite material. Inparticular, the composite material used in composite structures is agood conductor of heat and thus is able to dissipate heat away from thebraking surfaces that is generated in response to braking. Compositematerial is also highly resistant to heat damage, and is thus capable ofsustaining friction between brake surfaces during severe braking,without a significant reduction in the friction coefficient ormechanical failure.

SUMMARY

In various embodiments, a method for making a composite structure maycomprise rotating a base layer of an apparatus for forming the compositestructure about an axis of rotation, transferring carbon short fibersfrom a first vibratory feed ramp onto the base layer in order to form aplurality of fibrous layers in the composite structure, and/or vibratingthe first vibratory feed ramp during the transferring the carbon shortfibers. The base layer may comprise an annular shape.

In various embodiments, the method may further comprise cutting a carbonfiber strand into the carbon short fibers, wherein the carbon shortfibers may be between 0.5 inch and 2 inches in length, or between 0.75inch and 1.5 inches in length. In various embodiments, the method mayfurther comprise transferring the carbon short fibers from a firstloader onto the first vibratory feed ramp, wherein the first loadercomprises a loader hole comprising a first dimension and a seconddimension, wherein the first dimension is larger than the seconddimension, and the first dimension transfers the carbon short fibers toan outer edge of the first vibratory feed ramp. In various embodiments,the method may further comprise transferring additional carbon shortfibers from a supplemental vibratory feed ramp onto an outer diameterarea of the base layer. In various embodiments, the method may furthercomprise rolling the carbon short fibers with a roller in response tothe transferring the carbon short fibers. In various embodiments, themethod may further comprise compressing each of the plurality of fibrouslayers during the rotating the base layer at a compression zone of theapparatus. The method may further comprise disposing an innersacrificial edge along an inner diameter of the base layer and an outersacrificial edge along an outer diameter of the base layer. Thecompressing the plurality of fibrous layers may comprise needling eachof the plurality of fibrous layers during the rotating the base layer atthe compression zone of the apparatus.

In various embodiments, the method may further comprise transferring asecondary material from a second vibratory feed ramp onto the base layerof the apparatus, and/or vibrating the second vibratory feed ramp duringthe transferring the secondary material. In various embodiments, thesecondary material may comprise ceramic particles, powdery resin, carbonparticles, and/or graphite particles. The transferring the carbon shortfibers and the transferring the secondary material may occursimultaneously. In various embodiments, the method may further comprisedensifying the carbon structure by chemical vapor infiltration,pre-ceramic polymer infiltration, and/or silicon melt infiltration.

In various embodiments, the base layer may be disposed within a cavityhaving an annular shape. The method may further comprise transferring asecondary material from a second vibratory feed ramp into the cavityand/or vibrating the second vibratory feed ramp during the transferringthe secondary material. The secondary material may comprise ceramicparticles, powdery resin, carbon particles, and/or graphite particles.

In various embodiments, the method may further comprise pretreating acarbon fiber strand to form an interface coating on the carbon fiberstrand comprising at least one of pyrolytic carbon, boron nitride, orsilicon carbide, wherein the carbon fiber strand is cut into the carbonshort fibers. In various embodiments, the method may further comprisecutting a carbon fiber strand to form the carbon short fibers, whereinthe carbon short fibers are between 0.5 inch and 2 inches long. Invarious embodiments, the method may further comprise compressing each ofthe plurality of fibrous layers during the rotating the base layer at acompression zone of the apparatus. In various embodiments, the methodmay further comprise densifying the carbon structure by at least one ofchemical vapor infiltration, pre-ceramic polymer infiltration, orsilicon melt infiltration.

In various embodiments, an apparatus for forming a composite structuremay comprise a base layer that is annular in shape and configured torotate about an axis of rotation, a vibratory feed ramp configured totransfer carbon short fibers to the base layer, and/or a vibrationgenerator coupled to the vibratory feed ramp, wherein the vibrationgenerator is configured to generate vibrations to vibrate the vibratoryfeed ramp.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood with reference to thefollowing drawing figures and description. Non-limiting andnon-exhaustive descriptions are described with reference to thefollowing drawing figures. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingprinciples. In the figures, like referenced numerals may refer to likeparts throughout the different figures unless otherwise specified.

FIG. 1A illustrates a perspective view of a composite structure, inaccordance with various embodiments;

FIG. 1B illustrates a perspective view of a composite structure andcompression board, in accordance with various embodiments;

FIG. 2A illustrates a perspective view of a loom system with a vibratoryfeed ramp, in accordance with various embodiments;

FIG. 2B illustrates a top view of a loom system, in accordance withvarious embodiments;

FIG. 2C illustrates a perspective view of a loom system with multiplevibratory feed ramps, in accordance with various embodiments;

FIG. 3 illustrates a perspective view of a mold system, in accordancewith various embodiments;

FIGS. 4A and 4B illustrate perspective views of a loader and a vibratoryfeed ramp, in accordance with various embodiments;

FIG. 4C illustrates a perspective view of multiple loaders and multiplevibratory feed ramps, in accordance with various embodiments;

FIG. 5 illustrates a method of forming a composite structure, inaccordance with various embodiments; and

FIG. 6 illustrates an additional method of forming a compositestructure, in accordance with various embodiments.

DETAILED DESCRIPTION

All ranges may include the upper and lower values, and all ranges andratio limits disclosed herein may be combined. It is to be understoodthat unless specifically stated otherwise, references to “a,” “an,”and/or “the” may include one or more than one and that reference to anitem in the singular may also include the item in the plural.

The detailed description of various embodiments herein makes referenceto the accompanying drawings, which show various embodiments by way ofillustration. While these various embodiments are described insufficient detail to enable those skilled in the art to practice thedisclosure, it should be understood that other embodiments may berealized and that logical, chemical, and mechanical changes may be madewithout departing from the scope of the disclosure. Thus, the detaileddescription herein is presented for purposes of illustration only andnot of limitation. For example, the steps recited in any of the methodor process descriptions may be executed in any order and are notnecessarily limited to the order presented. Furthermore, any referenceto singular includes plural embodiments, and any reference to more thanone component or step may include a singular embodiment or step. Also,any reference to attached, fixed, connected, or the like may includepermanent, removable, temporary, partial, full, and/or any otherpossible attachment option. Additionally, any reference to withoutcontact (or similar phrases) may also include reduced contact or minimalcontact.

In the context of the present disclosure, systems and methods may findparticular use in connection with aircraft brake disks. However, variousaspects of the disclosed embodiments may be adapted for optimizedperformance with a variety of carbon fiber preforms and carbon/carbon(“C/C”) brake or clutch disks. As such, numerous applications of thepresent disclosure may be realized.

Carbon/carbon (“C/C”) parts in the form of friction disks are commonlyused for aircraft brake disks and race car brake and clutch disks. C/Cbrake disks are especially useful in these applications because of theirrelatively light weight and/or the superior high temperaturecharacteristics of C/C material. In particular, the carbon/carbonmaterial used in C/C parts is a good conductor of heat and is able todissipate heat generated during braking away from the braking surfaces.Carbon/carbon material is also highly resistant to heat damage, andthus, is capable of sustaining friction between brake surfaces duringsevere braking without a significant reduction in the frictioncoefficient or mechanical failure. As used herein the term “compositestructure” may be used to describe a carbon preform, a carbon fiberreinforced carbon material at various stages of densification, a carbonstructure prior to densification and carbon reinforcement, and/or afinished carbon composite material.

Referring to FIG. 1A, a composite structure 10 is shown, in accordancewith various embodiments. Composite structure 10 may be formed bysuperimposing a number of fibrous layers 12 on top of each other. Invarious embodiments, fibrous layers 12 may be made from carbon fibers,which may be oxidized polyacrylonitrile (PAN) fibers, which may bereferred to as “OPF” fibers. In various embodiments, fibrous layers 12may comprise one or more of OPF fibers, carbonized carbon fibers,phenolic based fibers, and/or pitched based fibers (collectively,“fibers”). Fibrous layers 12 may comprise one or more types of fibers.

With reference to FIGS. 1A and 1B, fibrous layers 12, or fiberscomprised in fibrous layers 12, may be disposed on top of one another.Fibrous layers 12 may be stacked on a base layer 13, which may be a bedplate and/or a transport layer, as discussed herein. In response to anew fibrous layer 12 or new fibers being disposed on top of previousfibrous layers 12 or fibers, the stack 44 of fibrous layers 12 may becompressed by compression board 16. Compression board 16 may move up anddown along axis 35 in a reciprocating manner, applying a compressiveforce to the fibers and/or fibrous layers 12. This compressive force maycause fibrous layers 12 to become more compact, and cause stack 44 toshorten from height 41 to compressed height 43. In various embodiments,compression board 16 may comprise one or more needles 14, which mayapply a compressive force during the movement of compression board 16along axis 35. The compressive force may compress a newly-added fibrouslayer 11 as shown in FIG. 1B, while compressing the entire stack 44. Inembodiments in which compression board comprises needles 14, barbedneedles may create z-fibers and stitch stack 44 together along the zaxis, thereby causing stack 44 to maintain the compressed height 43. Inresponse to the compressive force being applied by needles 14, thehorizontal fibers (in the x and y directions) are interconnected with athird direction (also called the z-direction). The fibers extending intothe third direction are also called z-fibers. Thus, after needling,composite structure 10 has fibers extending in three differentdirections (i.e., in the x and y directions in the plane of the fibrouslayers 12 and the z direction perpendicular to the fibrous layers 12).

As used herein, “compressive force”, “compress”, or the like by acompression board, such as compression board 16, may refer to thecompressing of fibrous layers by the compression board, in embodimentsin which the compression board does not comprise needles 14. As usedherein, in embodiments in which a compression board, such as compressionboard 16, comprises one or more needles 14, “compressive force”,“compress”, or the like by the compression board may refer to thepenetrating of needles 14 into the fibrous layer(s) 12, which may or maynot compress stack 44. As used herein, the terms “tow” and “cable” areused to refer to one or more strands of substantially continuousfilaments. Thus, a “tow” or “cable” may refer to a plurality of carbonfiber strands of substantially continuous filaments or a single strandof substantially continuous filament. A “textile” may be referred to asa “fabric” or a “tape.” As used herein, the unit “K” represents“thousand.” Thus, a 1K tow means a tow comprising about 1,000 strands ofsubstantially continuous filaments. Fewer or greater amounts of textilefibers may be used per cable in various embodiments. In variousembodiments disclosed herein, fabrics in accordance with variousembodiments may comprise tows of from 0.1K to about 100K, or from about12K to about 100K, and, in various embodiments, heavier tows comprisingabout 300K to about 320K. As used in this context only, the term “about”means plus or minus 5K.

Referring to FIGS. 2A and 2B, in accordance with various embodiments, anapparatus for forming a composite structure is depicted. With combinedreference to FIGS. 1B, 2A, and 2B, the apparatus for forming a compositestructure may be a loom system 100. Elements with the like elementnumbering between figures are intended to be the same and will not berepeated for the sake of clarity. In various embodiments, loom system100 may comprise a loom 150. Loom 150 may have an annular shape suchthat composite structures formed in loom 150 are the annular shape ofbrake disks. Loom system 100 may comprise a base layer 113 upon whichcarbon short fibers 121 may be disposed. In various embodiments, baselayer 113 may be a bed plate and/or a transport layer. The transportlayer may be disposed upon the bed plate. According to variousembodiments, stationary and/or movable bed plates in loom system 100 maybe utilized to produce net shape preforms, such as net shape carbonpreforms for brakes. Loom system 100 may be advantageously utilized toform a near net shape composite structure with minimum material waste.Stationary bed plates may be smooth bed plates, such that the materialto form the composite structure rotates over, and with respect to, thestationary bed plate to facilitate layering and/or needling the textile.Movable bed plates may be rotatable bed plates that comprise a surfacewhich generates friction between the bed plate and the material and/orthe transport layer such that the bed plates move and/or entrain thematerial to facilitate layering the material.

In various embodiments, a transport layer disposed on base layer 113 maybe configured to rotate about axis of rotation 111 in direction 141. Thebed plate under the transport layer may rotate with transport layer, orthe bed plate may remain stationary. Such rotation may be accomplishedby a turntable. The transport layer may comprise a robust, low costsubstrate, such as cotton, rayon, polyester, woven carbon fabric, and/orother low cost natural and/or synthetic yarns. Cotton may be used as thetransport layer because it burns cleanly and/or combusts completelyduring subsequent processing of the composite structure, such asdensification. In various embodiments, the transport layer may be acombination of a synthetic fiber base and a carbon fiber fabric topsurface. As desired, other fibers and/or combinations of variousmaterials may be used for the fabric substrate. The transport layer maybe fabricated in the shape of an annulus. The transport layer may be anydesired thickness. The transport layer, in response to being secured, atleast temporarily, to loom 150 and/or the bed plate may be a transportmechanism for carbon short fibers 121 which form fibrous layers 12 incomposite structure 10. In response to the targeted/predetermined numberof fibrous layers 12 being formed, in various embodiments, themechanisms securing the edges of the first layer may be released and thecomposite structure may be easily removed manually and/or mechanicallyfrom the loom 150.

In various embodiments, loom 150 may comprise a rotating inner crown 180and/or a rotating outer crown 185. Rotating inner crown 180 may beadjacent to and/or part of an inner diameter 152. Rotating outer crown185 may be adjacent to and/or part of an outer diameter 154. Rotatinginner crown 180 and/or rotating outer crown 185 may comprise one or morepins 182. Pins 182 may be configured to secure the transport layer torotating inner crown 180 and/or rotating outer crown 185. However, thetransport layer may be secured to rotating inner crown 180 and/orrotating outer crown 185 in any suitable manner including by bolts,clamps, adhesive, and/or the like. Additional information about thetransport layer, bed plates, and/or loom 150 may be found at U.S. patentapplication Ser. No. 14/286,077 filed on May 23, 2014 and entitled“Systems and Methods for Transport of Fibers to/from a CircularNeedle-Punching Loom”, which is incorporated by reference herein in itsentirety.

Base layer 113, which may be a bedplate and/or transport layer, may beconfigured to facilitate the forming of fibrous layers 12 by receivingcarbon short fibers 121 during rotation about axis of rotation 111.Carbon short fibers 121 may be transferred onto base layer 113 from afirst vibratory feed ramp 120. First vibratory feed ramp 120 maycomprise an outer edge 124 corresponding to outer diameter 154 of loom150 and/or base layer 113, and an inner edge 122 corresponding to innerdiameter 152 of loom 150 and/or base layer 113. Inner edge 122 and outeredge 124 may comprise walls configured to keep carbon short fibers 121on first vibratory feed ramp 120 as carbon short fibers 121 travel downfirst vibratory feed ramp 120 in direction 102. First vibratory feedramp 120 may have a surface upon which carbon short fibers 121 maytravel to base layer 113. Carbon short fibers 121 may be transferredonto first vibratory feed ramp 120 from a first loader 170. The amountand/or number of carbon short fibers 121 transferred from first loader170 to first vibratory feed ramp 120 may be controlled by a load celland/or a gravimetric feeder and controller.

In various embodiments, during the transfer of carbon short fibers 121from first vibratory feed ramp 120 to base layer 113, first vibratoryfeed ramp 120 may vibrate, which may facilitate the movement of carbonshort fibers 121 in direction 102 along first vibratory feed ramp 120,and/or facilitate the transfer of carbon short fibers 121 from firstvibratory feed ramp 120 to base layer 113. The vibration of firstvibratory feed ramp 120 may facilitate a uniform distribution of carbonshort fibers 121 onto base layer 113 between inner diameter 152 andouter diameter 154. A vibration generator 128 may be coupled to firstvibratory feed ramp 120 and/or loom 150, and may cause first vibratoryfeed ramp 120 to vibrate. In various embodiments, vibration generator128 may be comprised in first vibratory feed ramp 120. Vibrationgenerator 128 may generate vibrations at any suitable frequency andamplitude. In various embodiments, vibration generator 128 may causefirst vibratory feed ramp 120 to vibrate in a direction parallel to axisof rotation 111 or in a direction perpendicular to axis of rotation 111,or in any other suitable direction.

The areal weight of each fibrous layer 12 being formed in loom 150 maybe controlled by the rate of delivery of the carbon short fibers 121.The rate at which carbon short fibers 121 are delivered to base layer113 may be controlled by first vibratory feed ramp 120, the gravimetricfeeder and controller, and/or the vibration frequency and/or amplitudeof vibrations generated by vibration generator 128. For example, agreater vibrational frequency and/or amplitude may increase the transferrate of carbon short fibers 121 from first vibratory feed ramp 120 tobase layer 113. Additionally, the areal weight of each fibrous layer 12may be controlled by the rotation rate of base layer 113 about axis ofrotation 111. For example, the faster the rotation rate of base layer113, the fewer carbon short fibers 121 will be transferred from firstvibratory feed ramp 120 to base layer 113 per unit time on any givenportion of a fibrous layer 12 being formed in a composite structure 10.

In various embodiments, carbon short fibers 121 may comprise one or moreof OPF fibers, carbonized carbon fibers, phenolic based fibers, and/orpitched based fibers such as thermoset pitch fiber. Carbon fiberstrands, which may be comprised in carbon tows, may be cut to formcarbon short fibers 121. In various embodiments, carbon short fibers 121may have any suitable length. In various embodiments, carbon shortfibers 121 may have a length between 0.5 inch (1.27 centimeters) and 2.0inches (5.08 centimeters). In various embodiments, carbon short fibers121 may have a length between 0.75 inch (1.91 centimeters) and 1.5inches (3.81 centimeters). In various embodiments, carbon short fibers121 may have a length greater than 2.0 inches (5.08 centimeters), orless than 0.5 inch (1.27 centimeters). Carbon short fibers 121 with thedimensions described herein may be accurately metered and distributed bythe vibrations of first vibratory feed ramp 120 and vibrations generator128 during transfer from first vibratory feed ramp 120 to base layer113, without carbon short fibers 121 breaking or becoming tangled.

In various embodiments, loom system 100 may include a roller 160configured to flatten and compress carbon short fibers 121 that havebeen transferred from first vibratory feed ramp 120 to base layer 113.Roller 160 may be any suitable shape, such as conical or cylindrical,and may rotate about roller axis 161. In various embodiments, roller 160may remain in the same position on loom 150 and flatten and/or compresscarbon short fibers 121 as base layer 113 rotates about axis of rotation111 with respect to roller 160.

In various embodiments, base layer 113 may transport carbon short fibers121 to a compression zone 115. Compression zone 115 of loom system 100may comprise a compression board 116. Compression board 116 may beconfigured to move up and down along or parallel to axis 135 similar tocompression board 16 in FIG. 1B, in a reciprocating manner. In variousembodiments, compression board 116 may not comprise one or more needles114, and therefore, compression board 116 may compress carbon shortfibers 121 without creating z-fibers, as described herein. In variousembodiments, compression board 116 may comprise one or more needles 114,which penetrate carbon short fibers 121 of each fibrous layer 12 in thecomposite structure. In response, z-fibers may be formed in each fibrouslayer 12.

In various embodiments, with further reference to FIGS. 1B, 2A, and 2B,in response to being compressed by roller 160 and/or compression board116, carbon short fibers 121 may tend to be forced toward, or squeezedout, inner diameter 152 and/or outer diameter 154. Accordingly, invarious embodiments, an inner sacrificial edge 104 and/or an outersacrificial edge 106 may be disposed for each fibrous layer 12, whichmay occur simultaneously with the transferring of carbon short fibers121 from first vibratory feed ramp 120 to base layer 113. Innersacrificial edge 104 may be disposed along inner diameter 152 and outersacrificial edge 106 may be disposed along outer diameter 154 to preventcarbon short fibers 121, or other material, from being squeezed outinner diameter 152 and/or outer diameter 154. Inner sacrificial edge 104and/or outer sacrificial edge 106 may be disposed as continuous strands,or as segments 107. In various embodiments, Inner sacrificial edge 104and/or outer sacrificial edge 106 may be comprised of bands or strips offabric, or one or more carbon tows, which may comprise carbon fiberand/or synthetic fibers.

In operation, in various embodiments, referring to FIGS. 1A, 1B, 2A, and2B, carbon short fibers 121 may be continuously transferred from firstloader 170 to first vibratory feed ramp 120, and from first vibratoryfeed ramp 120 to base layer, base layer 113 may be disposed at the topof loom 150 to form the first fibrous layer 12 of carbon short fibers121. During such transfers of carbon short fibers 121, first vibratoryfeed ramp 120 may be vibrating because of vibration generator 128, andbase layer 113 may be rotating about axis of rotation 111. Roller 160may flatten carbon short fibers 121 as carbon short fibers reach roller160. Compression board 116 may compress, and/or needle (in embodimentsin which compression board 116 comprises needles 114), carbon shortfibers 121 in response to carbon short fibers reaching compression zone115. In response to base layer 113 making a full revolution, a fullfibrous layer 12 may be formed. In various embodiments, in response to afull fibrous layer 12 being formed, the base layer 113 may recess intoloom 150 along or parallel to axis 151 to allow space for a subsequentfibrous layer 12 to be formed. The process of creating fibrous layers 12is repeated until a desired thickness and/or number of fibrous layers 12of composite structure 10 is achieved.

In various embodiments, with reference to FIGS, 1B and 2C, a loom system200, which is an apparatus for forming a composite structure, maycomprise a second loader 270 and/or a second vibratory feed ramp 220. Asecond vibration generator 228 may be coupled to second vibratory feedramp 220. In various embodiments, one vibration generator may providevibrations to first vibratory feed ramp 120 and second vibratory feedramp 220. Second vibratory feed ramp 220 may comprise a second inneredge 222 corresponding to inner diameter 152, and a second outer edge224 corresponding to outer diameter 154. Second loader 270 may beconfigured to transfer a secondary material 221 to second vibratory feedramp 220. Second vibratory feed ramp 220 may be configured to transfersecondary material 221 in direction 202 to base layer 113.

Second vibration generator 228 may vibrate second vibratory feed ramp220 to facilitate the transfer of secondary material 221 from secondvibratory feed ramp 220 to base layer 113, the same as or similar to thetransfer of carbon short fibers 121 from first vibratory feed ramp 120to base layer 113 as described herein. Secondary material 221 may bedisposed on top of, and/or among, carbon short fibers 121 such thatsecondary material 221 is comprised in each fibrous layer 12 beingformed. Secondary material 221 and carbon short fibers 121 may beflattened by roller 160 and compressed by compression board 116 duringrotation of base layer 113. Compression board 116 may or may notcomprise needles 114. In various embodiments without needles 114, carbonshort fibers 121 and secondary material 221 may be compressed withoutbeing needled, such that no materials travel in the z-direction. Invarious embodiments, compression board 116 may compress the material(i.e., carbon short fibers 121 and/or secondary material 221) after thecompletion of each fibrous layer 12 (i.e., after each revolution of baselayer 113), or after the completion of multiple fibrous layers 12.

Referring to FIG. 3, in accordance with various embodiments, anapparatus for forming a composite structure is depicted, in accordancewith various embodiments. The apparatus for forming a compositestructure may be a mold system 300. Mold system 300 may comprise a firstloader 170 and a first vibratory feed ramp 120 to deliver carbon shortfibers 121, a second loader 270 and a second vibratory feed ramp 220 todeliver secondary material 221, a compression board 316, a firstvibration generator 128, and/or a second vibration generator 228. Invarious embodiments, compression board 316 may or may not comprise atleast one needle, such as needles 114 in FIGS. 2A and 2C. Elements withthe like element numbering between figures are intended to be the sameand will not be repeated for the sake of clarity. Mold system 300 maycomprise a cavity 319 within a mold 350. Mold 350 and cavity 319 mayhave an inner diameter 352 and an outer diameter 354. Cavity 319 maycomprise a floor or base layer 313 (similar to base layer 13 upon whichfibrous layers 12 are formed, as depicted in FIG. 1). In variousembodiments, base layer 313 may be a bedplate and/or transport layer(similar to bed plate and/or transport layer discussed in relation to inFIGS. 2A and 2B). In various embodiments, there may be no bedplateand/or transport layer, but only a floor of cavity 319 serving as baselayer 313. Base layer 313 may remain fixed at the bottom of cavity 319,or fixed at any desired position along the height of mold 350, so as tocreate a composite structure with a desired thickness.

In operation, in various embodiments, referring to FIGS. 1A, 1B, and 3,carbon short fibers 121 may be continuously transferred from firstloader 170 to first vibratory feed ramp 120, and from first vibratoryfeed ramp 120 to base layer 313 in cavity 319. During such transfers ofcarbon short fibers 121, first vibratory feed ramp 120 may be vibratingbecause of vibration generator 128, and base layer 313 and/or mold 350may be rotating about axis of rotation 111. In various embodiments, thebase layer 313 may be stationary in cavity 319, and mold 350 may rotateabout axis of rotation 111 during the transferring of carbon shortfibers 121 to first vibratory feed ramp 120. In various embodiments,secondary material 221 may be transferred from second vibratory feedramp 220 to base layer 313 in cavity at the same time as thetransferring of carbon short fibers 121 to first vibratory feed ramp120, such that secondary material 221 is disposed on top of or withincarbon short fibers 121. Secondary material 221 may be any materialdiscussed herein.

Compression board 316 may compress, and/or needle (in embodiments inwhich compression board 316 comprises needles 114, depicted in FIGS. 2Aand 2C) carbon short fibers 121 and/or secondary material 221 inresponse to carbon short fibers 121 and/or secondary material 221reaching compression zone 315 during rotation. In response to base layer313 and/or mold 350 making a full revolution, a full fibrous layer 12may be formed. In various embodiments, compression zone 315 may be anyarea of cavity 319 within mold 350. For example, compression zone 315,in which carbon short fibers 121 and/or secondary material 221 arecompressed, may be a portion of the base layer 313 in cavity 319. Invarious embodiments, the compression zone may be the entire area of thebase layer 313 in cavity 319, in which a compression board, such ascompression board 316, or a mold, such as mold 350, would positionitself so as to be able to allow compression of the entire annular areaof cavity 319. In various embodiments, compression of carbon shortfibers 121 and/or secondary material 221 may occur only after formationof all desired fibrous layers 12. The process of creating fibrous layers12 is repeated until a desired thickness and/or number of fibrous layers12 of composite structure 10 is achieved.

In various embodiments, referring to FIGS. 1A-1B, 2A-2C, and 3,secondary material 221 may comprise a ceramic material such as siliconcarbide, boron carbide, and/or any other suitable ceramic material. Invarious embodiments, secondary material 221 may comprise a powderyresin, carbon particles, and/or graphite particles. In variousembodiments, secondary material 221 may comprise a combination of any ofthe examples of secondary material 221 listed herein. In variousembodiments, secondary material 221 may comprise a different kind ofcarbon short fiber than the kind delivered by first vibratory feed ramp120, such as thermoset pitch fiber. In various embodiments, ceramicparticles of secondary material 221 may be less than 1 micron (3.94×10⁻⁵inch) in size. In various embodiments, particles of secondary material221 may be between 1 micron (3.94×10⁻⁵ inch) and 25 microns (9.84×10⁻⁴inch) in size. In various embodiments, particles of secondary material221 may be between 1 micron (3.94×10⁻⁵ inch) and 5 microns (1.97×10⁻⁴inch) in size. In various embodiments, particles of secondary material221 may be between 1 micron (3.94×10⁻⁵ inch) and 2 microns (7.87×10⁻⁵inch) in size. In various embodiments, particles of secondary material221 may be between 1.2 micron (4.72×10⁻⁵ inch) and 1.8 microns(7.09×10⁻⁵ inch) in size. In various embodiments involving compressionof carbon short fibers 121 and/or secondary material 221 by compressionboard 116 without needles 114, particles of secondary material 221 maybe greater than 2 microns (7.87×10⁻⁵ inch) in size. In variousembodiments, particles of secondary material 221 may be different sizesbetween 1 micron (3.94×10⁻⁵ inch) and 25 microns (9.84×10⁻⁴ inch),and/or carbon short fibers 121 may be different lengths from 0.5 inch(1.27 centimeters) and 2.0 inches (5.08 centimeters). Such varyinglengths of carbon short fibers 121 and/or particles of secondarymaterial 221 may allow optimum packing of carbon short fibers 121 and/orsecondary material 221 in each fibrous layer 12.

In various embodiments, the target fiber volume in a composite structureformed in embodiments in which compression board 116, 316 comprises atleast one needle 114 may be between 10% by volume and 30% by volume,between 15% by volume and 25% by volume, or between 18% by volume and25% by volume. In various embodiments involving compression of carbonshort fibers 121 and/or secondary material 221 by compression board 116,316 without needles 114, the target fiber volume in a compositestructure may be between 40% and 50% by volume, or less. In variousembodiments, the target volume of secondary material 221 in a compositestructure may be between 10% by volume and 30% by volume, between 15% byvolume and 25% by volume, or between 20% by volume and 25% by volume.

In various embodiments, there may be any number of additional loadersand/or vibratory feed ramps in a loom system, such as loom system 100,or a mold system, such as mold system 300, to add various materials tothe fibrous layers 12 of a composite structure. Additionally, carbonshort fibers 121, secondary material 221, and/or any other material tobe comprised in a composite structure may be transferred to the baselayer 113, 313 by only first loader 170 and first vibratory feed ramp120, or any number of loaders and vibratory feed ramps.

In various embodiments, carbon short fibers 121 and/or secondarymaterial 221 are disposed onto base layer 113, 313, which may be a bedplate and or a transport layer, as described herein. Therefore, anydescription involving base layer 113, 313 herein may be applied tovarious embodiments in which the apparatus for forming a compositestructure, for example a loom system, such as loom system 100, or moldsystem, such as mold system 300, comprises a bed plate and/or transportlayer as base layer 113, 313. Also, compression zone 115, 315 may be anyarea of loom 150 or mold 350, respectively. For example, compressionzone 115, 315, in which carbon short fibers 121 and/or secondarymaterial 221 are compressed, may be a portion of base layer 113, 313. Invarious embodiments, the compression area may be the entire area of baselayer 113, 313, in which a compression board, such as compression board116, 316, would position itself so as to be able to compress the entireannular area of base layer 113, 313.

Referring to FIGS. 4A and 4B, a loader 470 and a vibratory feed ramp 420are depicted, in accordance with various embodiments. Loader 470 andvibratory feed ramp 420 may be comprised in an apparatus for forming acomposite structure, for example, a loom assembly, such as loom system100 in FIGS. 2A and 2B, and/or in a mold assembly, such as mold system300 in FIG. 3, and may correspond to first loader 170 and firstvibratory feed ramp 120, or second loader 270 and second vibratory feedramp 220, respectively. Loader 470 may comprise any suitable shape. Invarious embodiments, loader 470 may comprise an output end 477 that islarger than an input end 478. Such a configuration prevents the materialto be delivered from experiencing as much pressure from material aboveas the pressure that would be experienced with a loader comprising anoutput end 477 that is the same or smaller than input end 478. However,loader 470 may comprise such configurations. Loader 470 may comprise arotating blade 475, which may rotate via a rotator 476 about an axis ofrotation 479. Rotating blade 475 may facilitate the transfer of material(i.e., carbon short fibers and/or secondary material) to vibratory feedramp 420.

In various embodiments, loader 470 may comprise a loader hole 471through which material may be transferred to vibratory feed ramp 420.With combined reference to FIGS. 2A, 2C, 3, 4A, and 4B, vibratory feedramp 420 may comprise an inner edge 422 and an outer edge 424. Inneredge 422 may correspond to inner diameter 152, 352. Outer edge 424 maycorrespond to outer diameter 154, 354. In operation, the base layer 113,313 may be rotating about axis of rotation 111. Therefore, the angularvelocity of outer diameter 154, 354 may be greater than the angularvelocity of inner diameter 152, 352. This may cause an uneven amount ofmaterial to be transferred from vibratory feed ramp 420 to base layer113, 313, in that the area of base layer 113, 313 proximate to outerdiameter 154, 354 may receive less material (such as carbon short fibers121 and/or secondary material 221) from vibratory feed ramp 420 than thearea of base layer 113, 313 proximate to inner diameter 152, 352.

In light of this possibly uneven distribution of material, in variousembodiments, loader hole 471 may comprise a first dimension 472corresponding to outer edge 424 of vibratory feed ramp 420 and outerdiameter 154, 354 that is larger than a second dimension 473 of loaderhole 471, which corresponds to inner edge 422 of vibratory feed ramp 420and inner diameter 152, 352. Therefore, more material (i.e., carbonshort fibers 121 and/or secondary material 221) may be transferred fromloader 470 to vibratory feed ramp 420 proximate to outer edge 424 andouter diameter 154, 354 to compensate for the greater angular velocityof outer diameter 154, 354.

In various embodiments, referring to FIGS. 2A-2C, 3, and 4C, the loaderhole may be any suitable shape with any suitable dimensions, includingsymmetrical shapes, such as loader hole 481. With loader hole 481 havinga first dimension 482 that is the same as a second dimension 483, invarious embodiments, loom system 100 and/or mold system 300 may compriseat least one a supplemental loader 770 and at least one supplementalvibratory feed ramp 720 to compensate for a possibly uneven distributionof material between inner diameter 152, 352 and outer diameter 154, 354.Supplemental loader 770 and/or supplemental vibratory feed ramp 720 maybe any suitable size relative to loader 470 and/or vibratory feed ramp420. Supplemental vibratory feed ramp 720 may comprise an outer edge 724that corresponds with outer edge 424 of vibratory feed ramp 420 andouter diameter 154, 354. Therefore, vibratory feed ramp 420 may delivera uniform amount of material to loom 150 or mold 350 between innerdiameter 152, 352 and outer diameter 154, 354, while supplemental loader770 and supplemental vibratory feed ramp 720 may provide additionalmaterial to an area proximate to outer diameter 154, 354 to compensatefor the greater angular velocity of outer diameter 154, 354.Supplemental vibratory feed ramp 720 may transfer the additionalmaterial to outer edge 424 of vibratory feed ramp 420 and/or directly tobase layer 113, 313. In various embodiments, supplemental vibratory feedramp 720 may comprise a supplemental vibration generator, similar tovibration generator 128, which causes supplemental vibratory feed ramp720 to vibrate. In various embodiments, loom system 100 and/or moldsystem 300 may comprise any suitable number of supplement loaders and/orsupplemental vibratory feed ramps to compensate for the greater angularvelocity of outer diameter 154, 354.

FIG. 5 depicts a method 500 for forming a composite structure, inaccordance with various embodiments. With combined reference to FIGS. 5and 2A-2C, carbon fiber strands may be cut (step 502) to lengthsdiscussed herein to form carbon short fibers 121. Carbon short fibers121 may be disposed in first loader 170, which may be in fluidcommunication with a first vibratory feed ramp 120. Carbon short fibers121 may be transferred from first loader 170 to first vibratory feedramp 120 (step 504), for example, through loader hole 471 or 481depicted and discussed in conjunction with FIGS. 4A-4C. During, or aspart of, step 504, an inner sacrificial edge 104 and/or an outersacrificial edge 106 may be disposed on base layer 113. As discussedherein, the base layer maybe a bed plate and/or transport layer. Innersacrificial edge 104 may be disposed along inner diameter 152 and outersacrificial edge 106 may be disposed along outer diameter 154 in orderto prevent carbon short fibers 121, or other material, from beingsqueezed out inner diameter 152 and/or outer diameter 154. Firstvibratory feed ramp 120 may be vibrated (step 506) by vibrationgenerator 128 to facilitate the transfer of carbon short fibers 121 fromfirst vibratory feed ramp 120 to base layer 113 in loom 150. Base layer113 may be rotated (step 508) about axis of rotation 111. Carbon shortfibers 121 may be transferred from first vibratory feed ramp 120 to baselayer 113 (step 510) to form fibrous layers 12 (depicted in FIGS. 1A and1B). Step 510 may occur while first vibratory feed ramp 120 is vibrating(step 506) and/or while base layer is rotating (step 508).

In various embodiments, a secondary material 221 may be transferred tobase layer 113 (step 512) via second loader 270 and second vibratoryfeed ramp 220. Second vibratory feed ramp 220 may be vibrated by secondvibration generator 228 during the transfer of secondary material 221from second vibratory feed ramp 220 to base layer 113. Secondarymaterial 221 may be a ceramic material, a carbon filler material, and/orany other suitable material, such as those described herein. Step 510and step 512 may occur simultaneously so carbon short fibers 121 areintermixed with secondary material 221. In various embodiments,material, such as carbon short fibers 121 and/or secondary material 221,may be transferred from a supplementary vibratory feed ramp 720 (step514) onto base layer 113 as described in connection with FIG. 4C herein.Carbon short fibers 121 and/or secondary material 221 may be rolled(step 516) by roller 160 so as to flatten carbon short fibers 121 and/orsecondary material 221.

In various embodiments, carbon short fibers 121 and/or secondarymaterial 221 may be compressed (step 518) in compression zone 115 bycompression board 116. Compression board 116 may or may not comprise oneor more needles 114 to needle the material and create z-fibers.Embodiments including ceramic materials as secondary material 221 may becompressed by compression board 116 without needles 114, thus carbonshort fibers would only be in the x and y-directions, with no z-fibers,as depicted in FIG. 1B, which may be called a “2D” or “two-dimensional”composite structure. Embodiments without ceramic materials as secondarymaterial 221 may be compressed by compression board 116 with needles114, thus forming z-fibers.

As described herein, with combined reference to FIGS. 1A, 1B, 2A-2C, and5 a fibrous layer 12 is formed with each revolution of base layer 113about axis of rotation 111 to form composite structure 10. Forming eachfibrous layer 12 may comprise any order or combination of steps 502through 518. After each revolution, base layer 113 may recess to makeroom for the next fibrous layer 12. In response to composite structure10 being formed by method 500 achieving a desired number of fibrouslayers 12 and/or a desired thickness, the composite structure 10 may beremoved from loom 150 comprising an annular net shape. A net shapecomposite structure 10, a preform in this case, indicates that theinitial production of the item is very close to the final (net) shape.

In various embodiments, composite structure 10 may then be densified(step 520) using any suitable densification method, such as at least oneof chemical vapor infiltration (CVI) (which may include pyrolytic carbonand/or silicon carbide), silicon melt infiltration, and/or pre-ceramicpolymer infiltration. Composite structure 10 may be removed from loom150 in order to be densified. In various embodiments employing CVI todensify composite structure 10, one or multiple CVI cycles may beemployed during densification. Each CVI cycle may be followed by a heattreatment. Heat treatment(s) following CVI cycles may be subjected at atemperature between 1600° C. (2912° F.) and 2400° C. (4352° F.). Siliconmelt may comprise composite structure 10 comprising a carbon/graphitematerial, silicon carbide fibers and/or particles, and/or boron carbideparticles, being heated while in contact with a source of silicon.Molten silicon infiltrates the porosity of composite structure 10 todensify composite structure 10. Pre-ceramic polymer infiltration maycomprise a pre-ceramic polymer being applied to composite structure 10.A pre-ceramic polymer may be polymer that can be pyrolyzed to form aceramic material, for example, a polycarbosilane resin, such as thatprovided by Starfire® Systems SMP-10. Composite structure 10 may besubjected to one or more polymer infiltration and pyrolysis (PIP)cycles, which may comprise being infiltrated by the pre-ceramic polymerand then pyrolyzed at temperatures ranging from 800° C. (1472° F.) to1800° C. (3272° C.) to form a ceramic material, such as silicon carbidefrom a pre-ceramic polymer of polycarbosilane resin.

In various embodiments, the system and methods described herein may beused to form composite structures comprising resin matrices, such asphenolic, epoxy, and/or polyester resins, and/or various otherhigh-temperature resins. In various embodiments, before or afterdensification of composite structure 10, composite structure 10 may bemachined or otherwise formed into a desired geometry.

FIG. 6 depicts a method 600 for forming a composite structure, inaccordance with various embodiments. With combined reference to FIGS.1A, 1B, 3, and 6, carbon strands may be pretreated (step 602). In orderto achieve desired friction and/or wear properties of a compositestructure 10, a carbon fiber tow may be heat treated to a temperaturebetween 1500° C. (2732° F.) and 2400° C. (4352° F.). Following heattreatment, an interface coating may be applied to each carbon fiberstrand within the carbon fiber tow. The interface coating may comprisepyrolytic carbon, boron nitride, and/or silicon carbide along eachcarbon fiber strand which is applied by chemical vapor disposition(CVD). The interface coating may have a thickness of between 0.2 micron(7.87×10⁻⁶ inch) and 0.5 micron (1.97×10⁻⁵ inch). In variousembodiments, the interface coating may have a thickness of between 0.3micron (1.18×10⁻⁵ inch) and 0.4 micron (1.57×10⁻⁵ inch). In variousembodiments, there may be multiple interface coatings on each carbonfiber strand comprising pyrolytic carbon, boron nitride, and/or siliconcarbide, each having a thickness of between 0.2 micron (7.87×10⁻⁶ inch)and 0.5 micron (1.97×10⁻⁵ inch), or between 0.3 micron (1.18×10⁻⁵ inch)and 0.4 micron (1.57×10⁻⁵ inch). The interface coating may protect thecarbon fiber in the carbon fiber strands from reacting with a ceramicmatrix that may be present in composite structure 10.

In various embodiments, the carbon fiber strands may be cut (step 604)to lengths discussed herein to form carbon short fibers 121. Carbonshort fibers 121 may be disposed in first loader 170, which may be influid communication with a first vibratory feed ramp 120. Carbon shortfibers 121 may be transferred from first loader 170 to first vibratoryfeed ramp 120 (step 606), for example, through loader hole 471 or 481depicted and discussed in conjunction with FIGS. 4A-4C. First vibratoryfeed ramp 120 may be vibrated (step 608) by vibration generator 128 tofacilitate the transfer of carbon short fibers from first vibratory feedramp 120 to cavity 319 of mold 350. Mold 350, and cavity 319 comprisedin mold 350, may be rotated (step 610). Cavity 319 may comprise a flooror base layer 313, which may be a bed plate and/or transport layer, suchas the transport layer discussed in relation to FIGS. 2A and 2B,. Baselayer 313 in cavity 319 may rotate with mold 350. Carbon short fibers121 may be transferred from first vibratory feed ramp 120 to cavity 319(step 612) to form fibrous layers 12 (depicted in FIGS. 1A and 1B). Step612 may occur while first vibratory feed ramp 120 is vibrating (step608) and while base layer 313 is rotating (step 610).

In various embodiments, a secondary material 221 may be transferred tointo cavity 319 (step 614) via second loader 270 and second vibratoryfeed ramp 220. Second vibratory feed ramp 220 may be vibrated (step 616)by second vibration generator 228 during the transfer of secondarymaterial 221 from second vibratory feed ramp 220 to cavity 319.Secondary material 221 may be any suitable material, such as thosediscussed herein. Step 612 and step 614 may occur simultaneously socarbon short fibers 121 are intermixed with secondary material 221. Invarious embodiments, additional material, such as carbon short fibers121 and/or secondary material 221, may be transferred from asupplementary vibratory feed ramp 720 (step 618) into cavity 319 asdescribed in connection with FIG. 4C herein.

In various embodiments, carbon short fibers 121 and/or secondarymaterial 221 in each fibrous layer 12 may be compressed (step 620) incompression zone 315 by compression board 316. In various embodiments,compression board 316 may not comprise one or more needles, andtherefore carbon short fibers 121 and/or secondary material 221 may becompressed by compression board 316 in the x and y-directions, asdepicted in FIG. 1B, forming a 2D composite structure. In variousembodiments, compression board 316 may comprise one or more needles,such as needles 114 depicted in FIGS. 2A-2C, forming z-fibers duringcompression by compression board 316.

As described herein, with combined reference to FIGS. 1A, 1B, 3, and 6 afibrous layer 12 is formed with each revolution of the base layer 313about axis of rotation 111 to form composite structure 10. Forming eachfibrous layer 12 may comprise any order or combination of steps 602-620.After each revolution, a new fibrous layer 12 may be formed. In responseto composite structure 10 being formed by method 600 achieving a desirednumber of fibrous layers 12 and/or a desired thickness, in variousembodiments, mold 350 may be closed with composite structure 10remaining in cavity 319 of mold 350, and composite structure 10 may bepartially densified (step 622) by any of the densification methodsdiscussed herein. During partial densification of composite structure 10during step 622, resin that infiltrated composite structure 10 may becured and/or pyrolyzed. In various embodiments, composite structure 10may be removed from mold 350 (step 624) and densified (Step 626) usingany of the densification methods discussed herein. In variousembodiments, composite structure 10 may be fully densified within mold350.

In various embodiments, the mold 350 and/or loom 150 may be comprised ofgraphite, aluminum, plastic, and/or any other suitable material. Mold350 may comprise perforated walls and a lid to close the mold in orderto allow densification of composite structure 10 within mold 350. Invarious embodiments, before or after densification of compositestructure 10, composite structure 10 may be machined or otherwise formedinto a desired geometry.

Implementing the various steps, techniques, combinations, compounds,etc. discussed herein, below are various examples of methods of formingcomposite structures.

EXAMPLE 1 Forming Carbon Composite with Carbonized Carbon Fiber

A smooth bed plate annular loom equipped with a vibratory feed ramp anda vibrations generator, and a transport layer made of a combinedcotton/woven carbon fabric, is used to prepare an annular compositestructure, a brake preform in this case. Carbon fiber strands are cutinto carbon short fibers with a length of about 0.75 inch (1.91 cm),wherein “about” as used in this context only means plus or minus 0.25inch (0.64 cm). The transferring speed of carbon short fibers to thetransport layer, and bed plate rotating speed are adjusted to formfibrous layers of 550 grams per square meter to 650 grams per squaremeter of carbon short fiber. Thirty fibrous layers are created. Thefibrous layers are compressed and needled by a compression boardcomprising a plurality of needles with a reciprocation rate of about 928RPM, wherein “about” as used in this context only means plus or minus 50RPM. Bed plate and/or transport layer may rotate at a speed of about 5.3turns/minute, wherein “about” as used in this context only means plus orminus 1 turn/minute. The oscillation rate and rotation speed are used tooptimize composite structure fabrication time corresponding to a carbonshort fiber feeding speed from the vibratory feed ramp to the bed plateand/or transport layer of about 0.5 kg (1.1 lbs.) per minute wherein“about” as used in this context only means plus or minus 0.25 kg (0.55lb.).

The composite structure is subsequently subjected to a heat treatment attemperatures between 1600° C. (2912° F.) and 2400° C. (4352° F.) anddensified using CVI pyrolytic carbon.

EXAMPLE 2 Forming Carbon Composite with Carbonized Carbon Fiber andThermoset Pitch Fiber

Similar equipment is used as Example 1 herein to prepare a carbonstructure comprising carbon short fibers. The carbon composite will alsocomprise thermoset pitch fibers to raise the thermal conductivity of thecomposite structure. The carbon short fibers are transferred onto bedplate and/or transport layer using a first loader and a first vibratoryfeed ramp which is vibrated by a first vibration generator. Thethermoset pitch fiber is transferred onto bed plate and/or transportlayer on top of the carbon short fibers using a second loader and secondvibratory feed ramp which is vibrated by a second vibration generator.The feed ratio of carbon short fiber to thermoset pitch fiber may be 75percent by volume to 25 percent by volume, respectively. In variousembodiments, the feed ratio of carbon short fiber to thermoset pitchfiber may be 85 percent by volume to 15 percent by volume, respectively.

The composite structure is subsequently subjected to a heat treatment attemperatures between 1600° C. (2912° F.) and 2400° C. (4352° F.) anddensified using CVI silicon carbide.

EXAMPLE 3 Forming a 2D Composite Structure

A perforated graphite mold set on a turntable for rotation is used inconjunction with a vibratory feed ramp vibrated by a vibration generatorto transfer carbon short fibers from the vibratory feed ramp to the moldin a controlled fashion. The carbon short fibers may be about 1 inch(2.54 centimeters) in length and the mold may be annular, wherein“about” as used in this context only means plus or minus 0.25 inch (0.64cm) Each fibrous layer formed may have an areal weight of about 800grams per square meter, wherein “about” as used in this context onlymeans plus or minus 100 grams per square meter. The composite structureis formed with 22 fibrous layers. The upper part of the graphite mold isclosed to ensure about a 25% fiber volume in the composite structure,wherein “about” as used in this context only means plus or minus 5%fiber volume. The composite structure is heat treated to temperaturebetween 1600° C. (2912° F.) and 2400° C. (4352° F.), and densified usingCVI pyrolytic carbon and machined to desired part geometry.

EXAMPLE 4 Forming a 2D Composite Structure using Pre-Ceramic PolymerInfiltration

A 50K carbonized carbon fiber tow is heat treated to about 2000° C.(3632° F.) (wherein “about” in this context only means plus or minus500° C. (900° F.)) and coated with a thin interface coating of pyrolyticcarbon of about 0.3 micron prior to cutting the tow into the carbonshort fibers, wherein “about” as used in this context only means plus orminus 0.2 micron (7.87×10⁻⁶ inch). A perforated aluminum mold rotatingon a turntable is used in conjunction with a first vibratory feed rampwhich is vibrated by a first vibration generator to transfer carbonshort fibers in a controlled fashion from the vibratory feed ramp to themold. The carbon short fibers may be about 0.75 inch long (1.91 cm)carbonized carbon fibers, wherein “about” as used in this context onlymeans plus or minus 0.25 inch (0.64 cm). A second vibratory feed ramp,which is vibrated by a second vibration generator, may transfer siliconcarbide powder to the annular cavity of the mold. The targeted fibervolume following compression of the fibrous layers by a compressionboard molding is about 30% fiber volume, wherein “about” as used in thiscontext only means plus or minus 10% fiber volume. Transferring of thecarbon short fibers and of the silicon carbide powder to the mold iscoordinated to achieve about 30% by volume carbon fiber and about 20% byvolume silicon carbide powder, wherein “about” as used in this contextonly means plus or minus 10% by volume. Fibrous layers of about 150grams per square meter of carbon fiber and about 176 grams per squaremeter of silicon carbide powder are formed in the cavity of the mold,wherein “about” as used in this context only means plus or minus 20grams per square meter. The closed perforated mold is first vacuuminfiltrated with a polycarbosilane resin such as that sold under themark Starfire® Systems SMP-10 pre-ceramic polymer and subsequentlycompression molded at about 300° C. (572° F.) to cure thepolycarbosilane resin, wherein “about” as used in this context onlymeans plus or minus 50° C. (90° F.). The partially densified 2Dcomposite structure is subsequently pyrolyzed to about 1800° C. (3272°F.) (wherein “about” as used in this context only means plus or minus500° C. (900° F.)) and subjected to multiples PIP cycles until finalporosity of the composite structure is between 10% and 15% by volume.

EXAMPLE 5 Forming a 2D Composite Structure using Pre-Ceramic PolymerInfiltration and CVI Silicon Carbide

A 24K carbonized carbon fiber tow is heat treated to about 2300° C.(4172° F.) (wherein “about” in this context only means plus or minus500° C. (900° F.)) and coated with a thin layer of pyrolytic carbon ofabout 0.3 micron prior to cutting the carbon fiber tow into carbon shortfibers, wherein “about” as used in this context only means plus or minus0.2 micron (7.87×10⁻⁶ inch). A perforated aluminum mold set on aturntable is used in conjunction with a first vibratory feed ramp whichis vibrated by a first vibration generator to transfer carbon shortfibers in a controlled fashion from the vibratory feed ramp to the mold.The carbon short fibers may be 1 inch long (2.54 cm) carbonized carbonfibers, wherein “about” as used in this context only means plus or minus0.25 inch (0.64 cm). A second vibratory feed ramp, which is vibrated bya second vibration generator, may transfer silicon carbide powder to theannular cavity of the mold. The targeted fiber volume followingcompression of the fibrous layers by a compression board molding isabout 21% fiber volume, wherein “about” as used in this context onlymeans plus or minus 10% fiber volume. Transferring of the carbon shortfibers and of the silicon carbide powder to the mold is coordinated toachieve about 21% by volume carbon fiber and about 10% by volume siliconcarbide powder, wherein “about” as used in this context only means plusor minus 5% by volume. Fibrous layers of about 150 grams per squaremeter of carbon fiber and 126 grams per square meter of silicon carbidepowder are formed in the cavity of the mold, wherein “about” as used inthis context only means plus or minus 20 grams per square meter. Theclosed perforated mold is first vacuum infiltrated with Starfire®Systems SMP-10 pre-ceramic polymer (polycarbosilane resin) andsubsequently compression molded at about 300° C. (572° F.) to cure theresin, wherein “about” as used in this context only means plus or minus50° C. (90° F.). The partially densified 2D composite structure issubsequently pyrolyzed to about 1800° C. (3272° F.) in an inertatmosphere (i.e., under nitrogen or argon gas), wherein “about” as usedin this context only means plus or minus 500° C. (900° F.). Thepartially densified 2D composite structure is subsequently densifiedusing CVI silicon carbide until final porosity of the compositestructure is between 10% and 15% by volume.

EXAMPLE 6 Forming a 2D Composite Structure using Silicon MeltInfiltration

A 50K carbonized carbon fiber tow is heat treated to about 2400° C.(4352° F.) (wherein “about” in this context only means plus or minus500° C. (900° F.)) and coated with a dual thin interface coating ofabout 0.3 micron pyrolytic carbon and about 0.3 micron silicon carbide(which was applied by chemical vapor disposition) prior to cutting thetow into the carbon short fibers, wherein “about” as used in thiscontext only means plus or minus 0.2 micron (7.87×10⁻⁶ inch). Aperforated aluminum mold rotating on a turntable is used in conjunctionwith a first vibratory feed ramp which is vibrated by a first vibrationgenerator to transfer carbon short fibers in a controlled fashion fromthe vibratory feed ramp to cavity of the mold. The carbon short fibersmay be about 0.75 inch long (1.91 cm) carbonized carbon fibers, wherein“about” as used in this context only means plus or minus 0.25 inch (0.64cm). A second vibratory feed ramp, which is vibrated by a secondvibration generator, may transfer boron carbide powder to the annularcavity of the mold. The targeted fiber volume following compression ofthe fibrous layers by a compression board molding is about 25% fibervolume, wherein “about” as used in this context only means plus or minus5% fiber volume. Transferring of the carbon short fibers and of theboron carbide powder to the mold is coordinated to achieve about 25% byvolume carbon fiber and about 10% by volume boron carbide powder,wherein “about” as used in this context only means plus or minus 5% byvolume. Fibrous layers of about 150 grams per square meter of carbonfiber and about 83 grams per square meter of boron carbide powder areformed in the cavity of the mold, wherein “about” as used in thiscontext only means plus or minus 20 grams per square meter. The closedperforated mold is first vacuum infiltrated with a phenolic resin andsubsequently compression molded to cure the resin. The carbon compositeis carbonized at about 1000° C. (1832° F.) in an inert atmosphere (i.e.,under nitrogen or argon gas), wherein “about” as used in this contextonly means plus or minus 500° C. (900° F.). Subsequently, the compositestructure is subjected to silicon melt in which a mixture of silicon,phenolic resin, and carbon black is applied to the composite structurecomprising boron carbide and melted to about 1450° C. (2642° F.),wherein “about” as used in this context only means plus or minus 500° C.(900° F.).

EXAMPLE 7 Forming a 2D Composite Structure using Silicon MeltInfiltration

A 24K carbonized carbon fiber tow is heat treated to about 2300° C.(4172° F.) (wherein “about” in this context only means plus or minus500° C. (900° F.)) and coated with a dual thin interface coating ofabout 0.3 micron pyrolytic carbon and about 0.3 micron silicon carbide(which was applied by chemical vapor disposition) prior to cutting thetow into the carbon short fibers, wherein “about” as used in thiscontext only means plus or minus 0.2 micron (7.87×10⁻⁶ inch). Aperforated aluminum mold rotating on a turntable is used in conjunctionwith a first vibratory feed ramp which is vibrated by a first vibrationgenerator to transfer carbon short fibers in a controlled fashion fromthe vibratory feed ramp to cavity of the mold. The carbon short fibersmay be about 0.75 inch long (1.91 cm) carbonized carbon fibers, wherein“about” as used in this context only means plus or minus 0.25 inch (0.64cm). A second vibratory feed ramp, which is vibrated by a secondvibration generator, may transfer boron carbide powder to the annularcavity of the mold. The targeted fiber volume following compression ofthe fibrous layers by a compression board molding is 40% fiber volume,wherein “about” as used in this context only means plus or minus 10%fiber volume. Transferring of the carbon short fibers and of the boroncarbide powder to the mold is coordinated to achieve 40% by volumecarbon fiber and 28% by volume boron carbide powder, wherein “about” asused in this context only means plus or minus 10% by volume. Fibrouslayers of about 150 grams per square meter of carbon fiber and about 145grams per square meter of boron carbide powder are formed in the cavityof the mold, wherein “about” as used in this context only means plus orminus 20 grams per square meter. The closed perforated mold is firstvacuum infiltrated with a phenolic resin and subsequently compressionmolded to cure the resin. The carbon composite is carbonized at about1000° C. (1832° F.) in an inert atmosphere (i.e., under nitrogen orargon gas), wherein “about” as used in this context only means plus orminus 500° C. (900° F.). Subsequently, the composite structure issubjected to silicon melt in which a mixture of silicon, phenolic resin,and carbon black is applied to the composite structure comprising boroncarbide and melted to about 1450° C. (2642° F.), wherein “about” as usedin this context only means plus or minus 500° C. (900° F.).

Benefits and other advantages have been described herein with regard tospecific embodiments. Furthermore, the connecting lines shown in thevarious figures contained herein are intended to represent exemplaryfunctional relationships and/or physical couplings between the variouselements. It should be noted that many alternative or additionalfunctional relationships or physical connections may be present in apractical system. However, the benefits, advantages, and any elementsthat may cause any benefit or advantage to occur or become morepronounced are not to be construed as critical, required, or essentialfeatures or elements of the disclosure. The scope of the disclosure isaccordingly to be limited by nothing other than the appended claims, inwhich reference to an element in the singular is not intended to mean“one and only one” unless explicitly so stated, but rather “one ormore.” Moreover, where a phrase similar to “at least one of A, B, or C”is used in the claims, it is intended that the phrase be interpreted tomean that A alone may be present in an embodiment, B alone may bepresent in an embodiment, C alone may be present in an embodiment, orthat any combination of the elements A, B and C may be present in asingle embodiment; for example, A and B, A and C, B and C, or A and Band C.

Systems, methods and apparatus are provided herein. In the detaileddescription herein, references to “various embodiments”, “oneembodiment”, “an embodiment”, “an example embodiment”, etc., indicatethat the embodiment described may include a particular feature,structure, or characteristic, but every embodiment may not necessarilyinclude the particular feature, structure, or characteristic. Moreover,such phrases are not necessarily referring to the same embodiment.Further, when a particular feature, structure, or characteristic isdescribed in connection with an embodiment, it is submitted that it iswithin the knowledge of one skilled in the art to affect such feature,structure, or characteristic in connection with other embodimentswhether or not explicitly described. After reading the description, itwill be apparent to one skilled in the relevant art(s) how to implementthe disclosure in alternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element is intended to invoke 35 U.S.C. 112(f)unless the element is expressly recited using the phrase “means for.” Asused herein, the terms “comprises”, “comprising”, or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus.

What is claimed is:
 1. A method for making a composite structure,comprising: rotating a base layer of an apparatus for forming thecomposite structure about an axis of rotation; transferring carbon shortfibers from a first vibratory feed ramp onto the base layer in order toform a plurality of fibrous layers in the composite structure; andvibrating the first vibratory feed ramp during the transferring thecarbon short fibers, wherein the base layer comprises an annular shape.2. The method of claim 1, further comprising cutting a carbon fiberstrand into the carbon short fibers, wherein the carbon short fibers arebetween 0.5 inch and 2 inches in length.
 3. The method of claim 1,further comprising cutting a carbon fiber strand into the carbon shortfibers, wherein the carbon short fibers are between 0.75 inch and 1.5inches in length.
 4. The method of claim 1, further comprisingtransferring the carbon short fibers from a first loader onto the firstvibratory feed ramp, wherein the first loader comprises a loader holecomprising a first dimension and a second dimension, wherein the firstdimension is larger than the second dimension, and the first dimensiontransfers the carbon short fibers to an outer edge of the firstvibratory feed ramp.
 5. The method of claim 1, further comprisingtransferring additional carbon short fibers from a supplementalvibratory feed ramp onto an outer diameter area of the base layer. 6.The method of claim 1, further comprising rolling the carbon shortfibers with a roller in response to the transferring the carbon shortfibers.
 7. The method of claim 1, further comprising compressing each ofthe plurality of fibrous layers during the rotating the base layer at acompression zone of the apparatus.
 8. The method of claim 7, furthercomprising disposing an inner sacrificial edge along an inner diameterof the base layer and an outer sacrificial edge along an outer diameterof the base layer.
 9. The method of claim 7, wherein the compressingcomprises needling each of the plurality of fibrous layers during therotating the base layer at the compression zone of the apparatus. 10.The method of claim 1, further comprising transferring a secondarymaterial from a second vibratory feed ramp onto the base layer of theapparatus, and vibrating the second vibratory feed ramp during thetransferring the secondary material, wherein the secondary materialcomprises at least one of ceramic particles, powdery resin, carbonparticles, or graphite particles.
 11. The method of claim 10, whereinthe transferring the carbon short fibers and the transferring thesecondary material occur simultaneously.
 12. The method of claim 1,further comprising densifying the carbon structure by at least one ofchemical vapor infiltration, pre-ceramic polymer infiltration, orsilicon melt infiltration.
 13. The method of claim 1, wherein the baselayer is disposed within a cavity having an annular shape.
 14. Themethod of claim 13, further comprising: transferring a secondarymaterial from a second vibratory feed ramp into the cavity; andvibrating the second vibratory feed ramp during the transferring thesecondary material.
 15. The method of claim 14, wherein the secondarymaterial comprises at least one of ceramic particles, powdery resin,carbon particles, or graphite particles.
 16. The method of claim 13,further comprising pretreating a carbon fiber strand to form aninterface coating on the carbon fiber strand comprising at least one ofpyrolytic carbon, boron nitride, or silicon carbide, wherein the carbonfiber strand is cut into the carbon short fibers.
 17. The method ofclaim 13, further comprising cutting a carbon fiber strand to form thecarbon short fibers, wherein the carbon short fibers are between 0.5inch and 2 inches in length.
 18. The method of claim 13, furthercomprising compressing each of the plurality of fibrous layers duringthe rotating the base layer at a compression zone of the apparatus. 19.The method of claim 14, further comprising densifying the carbonstructure by at least one of chemical vapor infiltration, pre-ceramicpolymer infiltration, or silicon melt infiltration.
 20. An apparatus forforming a composite structure, comprising: a base layer that is annularin shape and configured to rotate about an axis of rotation; a vibratoryfeed ramp configured to transfer carbon short fibers to the base layer;and a vibration generator coupled to the vibratory feed ramp, whereinthe vibration generator is configured to generate vibrations to vibratethe vibratory feed ramp.